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42

IT 2002 Order No BA 93-66-2201   Issue 01.06.08

7.4

Open the Power Unit

Open the power unit only if you are sufficiently qualified in

repairing electrical equipment.

Remove the 9 screws of the cover and remove the crane hook.
Remove the 5 screws of the side plate and remove the ground conductor from the

inside of the side plate.
Lift carefully the casing cover and remove the ground conductor from the inside of

the cover.
Now pull off the cover from the power unit.

Re-assemble the power unit in reverse sequence.

Make sure that no cables are jammed or sheared during

assembly.

Summary of Contents for 93-66-2201

Page 1: ...IT 2002 Power Unit 93 66 2201 Operating Manual...

Page 2: ...rasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com Web www hbs info com Copyright The information contained herein may not be copied reproduced adapted me...

Page 3: ...of malfunction In case of accident inform a physician and the responsible o cial body THREATTOLIFE Persons tted with a pace maker mu not operate the ud welding machine MAGNETICFIELDS During ud welding...

Page 4: ...e more copies please provide the order number li ed in the foot line Importantreminder Dataandinformationhereinwerecollectedwithgreate care Althoughwedidourvery be tocorrectlyupdateanyinformationuptot...

Page 5: ...e Welding Gun to the Power Unit 18 3 4 Ground Connection 19 3 5 Change Working Place 19 4 Function 20 4 1 Components of the Power Unit 20 4 1 1 Power Unit 20 4 1 2 Control Unit 21 4 2 Keyboard and Dis...

Page 6: ...he Weld 35 5 8 1 Visual Inspection 35 5 8 2 Bending Test 36 5 8 3 Arc Blow E ect 38 5 9 Malfunctions and Corrective Actions 39 6 Switching o the Power Unit 40 6 1 Temporary Switching off 40 6 2 Dispos...

Page 7: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 vii Glossary 58 Regulations and Standards 59 Further In ructions 61 Guarantee Clauses 62 Con rmation 63 Feedback 64 Service Support 65 Index 66...

Page 8: ...viii IT 2002 Order No BA 93 66 2201 Issue 01 06 08...

Page 9: ...powerunit Strictly observe the safety instructions Before starting up the power unit let the operator sign the confirmation that he shehasreadandfullyunderstoodtheoperatingmanual seeappendix Donotcomm...

Page 10: ...fthePowerUnit inChapter6 CareandMaintenance inChapter7 TechnicalDataandmuchmore inAppendix THREAT TO LIFE and risk of serious health and material damage in case of improper use of the power unit Obser...

Page 11: ...nual mean Threat to life or risk of personal injury Risk of material damage Ban for persons tted with a pace maker Warning of dangerous electrical voltage Warning of electromagnetic elds Wear protecti...

Page 12: ...itisintendedtoweldweldingelementsaccordingtoactualstandards see chapter 5 and appendix Any other use is regarded as not used as directed The manufacturerisnotliablefordamagesresultingfromthestudweldin...

Page 13: ...to be observed if the power unit is not to be put into operation immediatelyafterdelivery The power unit mu be ored in a secure place The power unit mu be protected again humidity du metallic dirt St...

Page 14: ...visible Type plate The type plate contains the following data Manufacturer Type OrderNo SerialNo Primaryvoltage Fuse Powerconsumption Cooling class Protection class Date Safety symbols Replace illegi...

Page 15: ...No BA 93 66 2201 Issue 01 06 08 15 2 Delivery Thebasicequipmentofyourpowerunitcontainsthefollowingcomponents No of pieces Part Type Order No 1 Powerunit IT 2002 93 66 2201 1 OperatingManual IT 2002 B...

Page 16: ...articles or liquids Before you start welding remove any combustible articles or liquids in vicinity of theworkplace Make sure that a fire extinguisher is within reach Never weld in rooms exposed to ri...

Page 17: ...rt any colleagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix 3 2 Connecting the Power Unit to the Primary Power Sup...

Page 18: ...that they are properly locked In case of loose connection heat may build up in the plug and may de roy the entire plug connection Plug the control cable in the connector of the power unit Twist the r...

Page 19: ...orcontaminantsfromtheworkpieceintheareaswhere you intend to connect the ground cables Connect the ground clamps to the workpiece as securely as possible Take care to ensure good contact and symmetrica...

Page 20: ...capacitors 9 Welding current stabilizer 5 Controlunit Afterpassingthemainsswitch 1 andtheEMC filter 2 themainsalternatingcurrent is converted in the bridge rectifier 3 The rectified voltage is smooth...

Page 21: ...lunitsynchronizesthemechanicalsequence liftingtheweldingelement with the electronic control ignition of pilot arc ignition of main arc sequence of welding time Theweldingtimeissteplessadjustable 4 2 K...

Page 22: ...shock and arc During the actual ud welding process do not touch the welding elements chuck or retaining nut nor any electrically conductive parts in their vicinity These are all electrically life Ste...

Page 23: ...ards see appendix non combu ibleclothes ear protection to current andards see appendix a protective apron over your clothes a protective headgear when welding overhead Before arting to weld remove all...

Page 24: ...ters a ash and a loud bang 90 dB A Alert any colleagues who are occupied in the vicinity of the welder Wear your personal protective equipment according to actual andards see appendix MAGNETICFIELDS D...

Page 25: ...ons seeappendix Drawn Arc Stud Welding The HBS stud welding unit operates by process of arc stud welding with drawn arc ignition accordingtothecurrentstandards seeappendix Thestandardsassignthis metho...

Page 26: ...ased on the use of welding elements which correspond with current standards seeappendix Variants of drawn arc ud welding Item Drawn arc stud welding with ceramic ferrule ring Drawn arc stud welding wi...

Page 27: ...ersolidification oftheweldpool Standardweldingelementsandceramicferrulesaredescribedinseveralstandards see appendix When using concrete anchors or shear connectors the front area can be plane construc...

Page 28: ...dershieldinggas With shielding gas you should only weld in position PA verti cal because due to gravity the shielding gas cannot prevent ow of the molten metal 5 2 3 Short Cycle Drawn Arc Stud Welding...

Page 29: ...chapter3 Starting up Check all cables and connections for proper condition Replace immediately defective cables and cable connections to avoid electrical shocks Check the chuck for proper seat see ope...

Page 30: ...50 0 36 1 6 3 2 600 0 33 1 6 3 2 11 1 0 437 0 9697 675 0 42 1 6 3 2 675 0 42 1 6 3 2 750 0 33 1 6 3 2 12 7 0 500 1 2671 800 0 55 1 6 3 2 800 0 55 1 6 3 2 875 0 46 1 6 3 2 15 9 0 625 1 9794 1200 0 67 2...

Page 31: ...tching on the Power Unit Improper operation of the ud welding unit is LIFE THREATENING Fir read the safety in ructions in chapters 1 3 and 5 Insert the primary plug of the power unit into an appropria...

Page 32: ...er unit is ready for welding Red on power unit is locked if the power unit is overheated displays show 8888 and LED lights After a short cooling period the work can continue Red on power unit is locke...

Page 33: ...e pre selected weldingcurrent In addition you can modify the welding time and welding current individually by pressingthearrowkeys asdescribedabove 5 6 4 Conversion Current Curve It is possible to adj...

Page 34: ...Wear always your personal protective equipment according to actual andards see appendix Insert the welding element into the chuck As soon as the power unit is ready for the welding process place the w...

Page 35: ...ding element w ithin tolerance after w elding Correct parameters None Contraction of w eld collar Plunging depth or lift too low Increase plunging depth check lift and centering of the ceramic ring w...

Page 36: ...rections The bending te is passed if a crack or a fracture of the welded zone does not occur Please note the in ructions on fault recognition and corrective actions in chapter 5 You don t need to te a...

Page 37: ...lement above weld collar Correct parameters none Fracture in the weld metal Many pores Welding energy too low Plunging speed too low Unsuitable stud base material combination Increase welding energy I...

Page 38: ...ddeflectionofthearc Itcauses asingle sidedmeltingofthestudmaterial increasedporeformation andundercutsin theweldingarea The arc blow effect is proportional to the current and can be influenced by symm...

Page 39: ...electrical flow w ith triggered start button Replace w elding gun trigger button Qualified personnel Control cable broken Check control cable for electrical flow Replace control cable Qualified perso...

Page 40: ...ly 6 1 Temporary Switching o Switch off the power unit Unplug the control cable and the welding cable from the power unit Protect the power unit against ingress of fluids and foreign bodies 6 2 Dispos...

Page 41: ...imary plug Do not wear a wri watch or any electrically conductive jewellery 7 2 Regular Maintenance Operations Clean the inner components of the power unit periodically of du Use a dry washcloth or a...

Page 42: ...ent Removethe9screwsofthecoverandremovethecranehook Removethe5screwsofthesideplateandremovethegroundconductorfromthe inside of the side plate Liftcarefullythecasingcoverandremovethegroundconductorfrom...

Page 43: ...luminum Welding rate Dia 7 8 7 uds min dia 22 mm 7 uds min Weldingcurrent 2 000 A max Currentadju mentrange 300 to 2 000 A epless Welding time 5 to 1 500 msec epless Primarypower 480 460V 3phases 50 6...

Page 44: ...rt complete 21 4 80 90 198 Washer 6 mm 23 4 80 90 147 Spring washer 6 mm 25 2 80 90 146 Nut M6 27 2 80 90 296 Screw M6 x 12 31 1 88 16 254 Rear wall complete 33 8 80 90 446 Screw M6 x 10 39 1 88 16 25...

Page 45: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 45 Power unit type IT 2002 93 66 2201...

Page 46: ...A 32 25 8 80 90 134 Screw M6 x 35 31 1 88 16 246 Conductorrailcomplete 40 3 80 90 217 Washer 10 mm 41 3 80 90 295 Springwasher10mm 42 3 80 90 294 Screw M10 x 25 45 1 80 50 04382 Synchronizingcomponent...

Page 47: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 47 Basic set up complete IT 2002 88 16 268...

Page 48: ...4 x 14 13 4 80 90 153 NutM4 19 1 80 80 558023 ElectronicboardITprocessor 21 4 88 11 784 Distancesleeve 23 4 80 11 415 Distance stud 29 3 80 50 035 Mountingsleeve 31 1 88 16 865 Groundconnector 33 4 80...

Page 49: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 49 Front assembly complete IT 2002 88 16 269023...

Page 50: ...lock washer 4 mm 41 3 80 90 164 Washer 4 mm 43 3 80 90 110 Screw M4 x 8 47 1 0 m 88 16 455 Cable channel 31 x 63 x 385 49 1 0 m 88 16 454 Cable channel 31 x 63 x 345 51 6 80 90 289 Screw M4 x 12 83 1...

Page 51: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 51 131 1 80 50 640 Plug 135 2 80 50 1441 Pole connector 14 P 137 4 80 50 2641 Pole connector 26 P...

Page 52: ...nferrite 23 1 88 16 332 Transformer480V 25 1 80 80 597 P C boardARCtransformer 27 4 80 90 164 Washer 4 mm 29 4 80 90 121 Springwasher4mm 31 4 80 90 110 Screw M4 x 8 37 2 80 50 0301 Neozedfuse base Gr...

Page 53: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 53 Country module USA complete IT 2002 88 17 930...

Page 54: ...stud M6 9 2 80 90 147 Springwasher6mm 11 2 80 90 146 NutM6 15 2 88 16 747 Contact block 17 2 80 90 458 Screw M10 x 35 19 2 80 90 217 Washer 10 mm 21 2 80 90 295 Springwasher10mm 25 1 88 17 191 Suppor...

Page 55: ...06 08 55 Setting the ud welding unit to the correct primary voltage Insert jumper see center of picture to the corresponding phase 420 V 440 V 460 V or 480 V Using a power unit set to an incorrect pri...

Page 56: ...56 IT 2002 Order No BA 93 66 2201 Issue 01 06 08 8 3 Circuit Diagram...

Page 57: ...A 93 66 2201 Issue 01 06 08 57 8 4 Environmentally Admissible Disposal Afterrepairofthepowerunit disposereplacedpartsinanenvironmentally admissibleway Usedmaterials Steel Nonferrousmetals brass copper...

Page 58: ...rect current Stud feeder Device for the automatic stud feeding of welding elements Studweldingunit Powerunitinclusiveweldinggun Thyristor Electroniccomponent contactlessswitch whichwilllet thecurrento...

Page 59: ...ud welding method for metals General DVS0902 Drawn arc udwelding DVS0903 Capacitor discharge ud welding with tip ignition DVS0904 In ructions for practice Arc ud welding DVS2927 Resi or projection wel...

Page 60: ...compatiblity EMC requirements Personalsafetyandaccidentprevention DIN EN ISO 20345 Personalprotectiveequipment Safetyfootwear DINEN12477 Protectiveglovesforwelders DIN EN 166 Personal eye protection...

Page 61: ...3 8 2 2 3 1 3 2 4 5 M8 8 0 15 0 4 9 9 5 4 0 7 5 6 0 11 0 M10 13 0 30 0 7 8 19 0 M12 19 0 53 0 12 0 33 0 M16 35 0 135 0 22 0 82 0 Steel 4 8 1 0 18 Rp0 2 340 N mm 2 1 4301 03 A2 50 0 18 Rp0 2 210 N mm...

Page 62: ...ncelledifrepairoperationsarecarriedoutbyunauthorized persons Warning Unauthorized interference with the ud welding unit as well as unauthorized alteration of the ud welding unit are prohibited and res...

Page 63: ..._____________________ ________________ ___________________________________ ________________ ___________________________________ ________________ ___________________________________ ________________ __...

Page 64: ...________________ 85221 Dachau Germany __________________________ Po fach 13 46 __________________________ 85203 Dachau Germany __________________________ Productdescription __________________________...

Page 65: ...IT 2002 Order No BA 93 66 2201 Issue 01 06 08 65 Service Support...

Page 66: ...ivery 10 15 display 21 disposal 40 disposal environmentallyadmissible 57 distancedevice 34 DVSregulations 34 E earprotection 9 23 electrical shock risk of 18 electricalvoltage 11 14 22 electromagnetic...

Page 67: ...protectiveequipment personal 9 protectivegloves 23 protectivegoggles 9 punchedplates 29 punchedplates welding to 29 R rectifier 58 recycling 57 regulations 59 repair 57 requirementsofworkplace 16 29...

Page 68: ...weld checking the quality of the 35 weldingelement 58 weldingelements 12 30 weldingelements lot of 30 weldinggun 12 58 weldingguncables 18 weldinggunsupport 34 weldingparameters 34 58 weldingparamete...

Page 69: ......

Page 70: ...HBS Bolzenschweiss Sy eme GmbH Co KG Felix Wankel Strasse 18 85221 Dachau Germany Phone 49 0 8131 511 0 Fax 49 0 8131 511 100 E mail po hbs info com www hbs info com...

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